differential TOYOTA TERCEL 1996 Service User Guide

PP3IZ-01
PP-52
- PREPARATIONSUSPENSION AND AXLE
99 Author
: Date
:
1996 TERCEL (RM440U)
SUSPENSION AND AXLE
SST (Special Service Tools)
09223-00010Cover & Seal ReplacerRear suspension
09223-15020Oil Seal & Bearing ReplacerFront axle
09308-00010Oil Seal PullerFront axle
Rear axle
09309-36010Transmission Rear Bearing
ReplacerFront drive shaft
09316-2001 1Transfer Bearing ReplacerFront drive shaft
09520-00031Rear Axle Shaft PullerFront axle
09550-10013Replacer Set ºBºRear axle
(09553-10010)Differential Side Bearing
Replacer
(09557-1001 1)Differential Drive Pinion
Front Bearing Replacer
09608-10010Steering Knuckle Oil Seal
ReplacerFront axle
09608-16042Front Hub Bearing Adjusting ToolFront drive shaft
(09608-02021)Bolt & Nut

SS0KP-02
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-25
155 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE
SERVICE DATA
Input shaft roller bearing journal diameterMin.24.970 mm (0.9831 in.)
Input shaft 3rd gear journal diameterMin.30.970 mm (1.2193 in.)
Input shaft 4th gear journal diameterMin.28.970 mm (1.1405 in.)
Input shaft 5th gear journal diameter (for C151)Min.24.870 mm (0.9791 in.)
Input shaft runoutMax.0.05 mm (0.0020 in.)
Output shaft roller bearing journal diameterMin.32.970 mm (1.2980 in.)
Output shaft 1st gear journal diameterMin.37.970 mm (1.4949 in.)
Output shaft 2nd gear journal diameterMin.31.970 mm (1.2587 in.)
Output shaft runoutMax.0.05 mm (0.0020 in.)
Gear thrust clearance 1st STD
Max.0.10 - 0.40 mm (0.0039 - 0.0157 in.)
0.45 mm (0.0177 in.)
Gear thrust clearance 2nd STD
Max.0.10 - 0.45 mm (0.0039 - 0.0177 in.)
0.50 mm (0.0197 in.)
Gear thrust clearance 3rd STD
Max.0.10 - 0.35 mm (0.0039 - 0.0138 in.)
0.40 mm (0.0157 in.)
Gear thrust clearance 4th STD
Max.0.10 - 0.55 mm (0.0039 - 0.0217 in.)
0.60 mm (0.0236 in.)
Gear thrust clearance 5th (for C151) STD
Max.0.10 - 0.57 mm (0.0039 - 0.0224 in.)
0.65 mm (0.0256 in.)
1st, 2nd, 3rd, 4th and 5th (for C151) gear radial clearance STD
Max.0.015 - 0.058 mm (0.0006 - 0.0023 in.)
0.070 mm (0.0028 in.)
Shift fork to hub sleeve clearance Max.1.0 mm (0.039 in.)
Synchronizer ring to gear clearance Min.0.6 mm (0.024 in.)
Drive in depth
Input shaft front oil seal
Speedometer driven gear oil seal
Control shaft cover oil seal
Select inner lever slotted spring pin
No. 1 shift inner lever slotted spring pin
No. 2 shift inner lever slotted spring pin
Transmission case oil seal
Transaxle case oil seal
15.8 ± 0.2 mm (0.622 ± 0.008 in.)
25 mm (0.98 in.)
1.0 - 2.0 mm (0.039 - 0.079 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
2.4 ± 0.3 mm (0.094 ± 0.012 in.)
1.9 ± 0.3 mm (0.075 ± 0.012 in.)
Differential side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Differential side gear thrust washer thickness1.50 mm (0.0591 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
Differential side bearing preload (at starting) (for use with SST)
New bearing
Reused bearing
0.8 - 1.6 N´m (8 - 16 kgf´cm, 6.9 - 13.9 in.´lbf)
0.5 - 1.0 N´m (5 - 10 kgf´cm, 4.3 - 8.7 in.´lbf)

SS-26
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
156 Author
: Date
:
1996 TERCEL (RM440U) Input shaft snap ring thickness
No. 2 clutch hub Mark 0
1
2
3
4
5
No. 3 clutch hub (for C151) Mark A
B
C
D
E
F
G
Input shaft rear bearing Mark A
B
C
D
E
F
2.30 mm (0.0906 in.)
2.36 mm (0.0929 in.)
2.42 mm (0.0953 in.)
2.48 mm (0.0976 in.)
2.54 mm (0.1000 in.)
2.60 mm (0.1024 in.)
2.25 mm (0.0886 in.)
2.31 mm (0.0909 in.)
2.37 mm (0.0933 in.)
2.43 mm (0.0957 in.)
2.49 mm (0.0980 in.)
2.55 mm (0.1004 in.)
2.61 mm (0.1028 in.)
2.29 mm (0.0902 in.)
2.35 mm (0.0925 in.)
2.41 mm (0.0949 in.)
2.47 mm (0.0972 in.)
2.53 mm (0.0996 in.)
2.59 mm (0.1020 in.)
Output shaft snap ring thickness
No. 1 clutch hub Mark A
B
C
D
E
F
2.50 mm (0.0984 in.)
2.56 mm (0.1008 in.)
2.62 mm (0.1031 in.)
2.68 mm (0.1055 in.)
2.74 mm (0.1079 in.)
2.80 mm (0.1102 in.)
Differential side bearing adjusting shim thickness Mark A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
U2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
2.90 mm (0.1142 in.)
2.95 mm (0.1161 in.)
3.00 mm (0.1181 in.)

SS0KQ-04
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-27
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head
14 mm head
10 mm head64
46
7.4650
470
7547
34
65 in.´lbf
Engine left mounting bracket x Insulator4849036
Engine rear mounting insulator x Body7880058
Engine rear mounting insulator x Bracket B bolt
C bolt64
90650
92047
67
Front exhaust pipe clamp set bolt1919014
Front exhaust pipe x Exhaust manifold6263046
Starter x Transaxle3940029
Clutch release cylinder x Transaxle121209
Shift lever assembly x Body121209
Grommet retainer x Body4.95043 in.´lbf
Retainer x Body4.95043 in.´lbf
Output shaft front bearing lock plate set bolt1111 58
Transmission case x Transaxle case2930022
Reverse shift arm bracket1717513
Straight screw plug (Reverse restrict pin) (C151)
Straight screw plug13
13130
1309
9
Straight screw plug (Shift fork shaft)2525018
Straight screw plug (Lock ball assembly) (C151)
Straight screw plug (C141)39
39400
40029
29
Reverse idler gear shaft lock bolt2930022
Rear bearing retainer2728020
Output shaft lock nut11 81,20087
Shift fork and shift head x Shift fork shaft1616012
Shift and select lever assembly2020014
Transmission case x Transmission case cover1818513
Back-up light switch4041030
Filler and drain plugs3940029
Ring gear x Differential case1241,26091
Speedometer driven gear1111 58
Control lever housing support bracket x Transmission case1111 58
Selecting bellcrank assembly x Transmission case2525018
Shift and select lever shaft assembly lock bolt2930022
Transaxle case receiver x Transaxle case1111 58
No. 1 and No. 2 oil receiver pipe1717513

SS0LK-02
SS-28
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A132L)
158 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A132L)
SERVICE DATA
Governor pressure Vehicle speed reference
30 km/h (19 mph)
60 km/h (37 mph)
90 km/h (56 mph)
59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
186 - 265 kPa (1.9 - 2.7 kgf/cm2, 27 - 38 psi)
353 - 431 kPa (3.6 - 4.4 kgf/cm2, 51 - 63 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
363 - 422 kPa (3.7 - 4.3 kgf/cm2, 53 - 61 psi)
530 - 706 kPa (5.4 - 7.2 kgf/cm2, 77 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,412 - 1,647 kPa (14.4 - 16.8 kgf/cm2, 205 - 239 psi)
Engine stall revolution D and R positions2,300 ± 200 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position750 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)
Between boot end face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Torque converter clutch installation distance
Drive plate runoutMax.
Torque converter clutch runout Max.More than 13.0 mm (0.512 in.)
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
Differential oil seal drive in depth0 ± 0.5 mm (0 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth19 mm (0.75 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
L position
Throttle valve fully closed 2 " 1
47 - 62 km/h (29 - 39 mph)
91 - 107 km/h (57 - 66 mph)
85 - 104 km/h (53 - 65 mph)
36 - 46 km/h (22 - 29 mph)
39 - 49 km/h (24 - 30 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
63 - 72 km/h (39 - 45 mph)
59 - 68 km/h (37 - 42 mph)

SS0LI-04
SS-30
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A242L)
160 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A242L)
SERVICE DATA
Governor pressure Vehicle speed reference
30 km/h (19 mph)
60 km/h (37 mph)
90 km/h (56 mph)
59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
196 - 275 kPa (2.0 - 2.8 kgf/cm2, 28 - 40 psi)
363 - 441 kPa (3.7 - 4.5 kgf/cm2, 53 - 64 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
373 - 422 kPa (3.8 - 4.3 kgf/cm2, 54 - 61 psi)
549 - 706 kPa (5.6 - 7.2 kgf/cm2, 80 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,638 - 1,902 kPa (16.7 - 19.4 kgf/cm2, 238 - 276 psi)
Engine stall revolution D and R positions2,300 ± 200 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position750 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)
Between boot end face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Torque converter clutch installation distance
Drive plate runoutMax.
Torque converter clutch runout Max.More than 13.0 mm (0.512 in.)
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
Differential oil seal drive in depth LH side
RH side5.3 ± 0.5 mm (0.209 ± 0.020 in.)
3.1 ± 0.5 mm (0.122 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth25.0 mm (0.98 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
Throttle valve fully closed 3 O/D
L position
Throttle valve fully closed 2 " 1
45 - 61 km/h (28 - 38 mph)
89 - 106 km/h (55 - 66 mph)
83 - 102 km/h (52 - 63 mph)
83 - 43 km/h (19 - 27 mph)
19 - 33 km/h (12 - 21 mph)
44 - 56 km/h (27 - 35 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
65 - 76 km/h (40 - 47 mph)
61 - 72 km/h (38 - 45 mph)

MX07Z-04
Z18913
Clutch Release Bearing
Clutch Release Fork
Clutch Release Fork Boot
Clutch Release Fork Support
Oil Seal
Oil Seal
Transaxle Case
Oil Seal
Input Shaft Front Bearing
Output Shaft Cover
Output Shaft Front Bearing
Bearing Lock Plate
 Non-reusable partSpeedometer Driven Gear
Control Lever Housing
Support Bracket
Transaxle Case Receiver
Differential Case Assembly Outer Race Magnet
Plate Washer
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-7
719 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

N00047
CM0141
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-15
1996 TERCEL (RM440U)
(e) C151:
Using a magnetic finger, remove the 2 balls from the re-
verse shift fork.
(f) Remove the No.3 shift fork shaft and reverse shift fork.
(g) Pull out the No.1 shift fork shaft.
(h) Remove the No.1 and No.2 shift forks.
24. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER
FROM TRANSAXLE CASE
25. REMOVE DIFFERENTIAL CASE ASSEMBLY
HINT:
Before reassembly, inspect the differential side bearing pre-
load.
26. REMOVE MAGNET FROM TRANSAXLE CASE
27. REMOVE NO.3 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.3 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs
from the No.3 clutch hub.

MX07U-03
Q06511

Oil Seal
Plate Washer

Outer Race and Side Bearing
Speedometer Drive Gear
Straight Pin

Side Bearing and Outer Race

Oil Seal
Ring Gear Plate Washer Differential Case Pinion Shaft
Pinion Gear
Thrust Washer
Side Gear
Thrust Washer

Non-reusable partx6
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-35
747 Author
: Date
:
1996 TERCEL (RM440U)
DIFFERENTIAL CASE
COMPONENTS

MX07V-03
Z16129
SST
MT0081
Matchmarks
MT0083
MT0084
N00098
SST MX-36
- MANUAL TRANSAXLEDIFFERENTIAL CASE
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
(a) Using SST, remove the bearings from both sides of the
case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00360)
(b) Remove the speedometer drive gear from the RH side.
2. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and case.
(b) Remove the 6 bolts.
(c) Using a plastic hammer, remove the ring gear from the
case.
3. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear
while holding one pinion toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washer to the side gears.
4. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, remove the pinion shaft
straight pin.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinion gears and side gears with the 4
thrust washers from each gear.
5. Transmission Case Side:
IF NECESSARY, REPLACE OIL SEAL AND SIDE
BEARING OUTER RACE
(a) Using a screwdriver and hammer, remove the oil seal.
(b) Using SST, remove the outer race and plate washer.
SST 09612-65014
(c) Place the plate washer into the case.